Grooved forged carbon steel fitting apparatus and methods of manufacturing the same

ABSTRACT

Roll grooved pipe fittings useful in the assembly of a variety of mechanically joined piping systems. These pipe fittings are roll grooved so that they can be mechanically joined directly with other like pipe fittings and/or with roll grooved straight pipe thereby substantially simplifying assembly. In addition, hybrid pipe fittings and systems are also disclosed. Methods and apparatus for manufacturing these aforementioned roll grooved pipe fittings are also disclosed and address both the roll grooving process itself, as well as various methodology and apparatus for correcting deformations that can occur as a result of the roll grooving process. Methods for using the aforementioned apparatus are also disclosed.

PRIORITY

This application is a divisional of, and claims the benefit of priorityto, U.S. patent application Ser. No. 13/417,077 filed Mar. 9, 2012 andentitled “Grooved Pipe Fitting Apparatus and Methods of Using andManufacturing the Same”, which in turn claims priority to U.S.Provisional Patent Application Ser. No. 61/452,038 filed Mar. 11, 2011of the same title, each of which being incorporated herein by referencein its entirety.

COPYRIGHT

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent files or records, but otherwise reserves all copyrightrights whatsoever.

FIELD OF THE INVENTION

The present invention relates generally to the area of groovedmechanical joining systems, and more specifically in one exemplaryaspect to improved apparatus and methods of manufacturing relating tothe use of grooved pipe fittings in, e.g., a piping system.

DESCRIPTION OF RELATED TECHNOLOGY

Mechanically joined piping systems are well known in a variety ofindustries and for a variety of applications involving the movement ofvarious fluids. Mechanically joined piping systems are in many instancesmore cost-effective to install then alternative piping systems such aswelded piping systems as it generally requires less skilled labor forinstallation as well as requires less time to install over weldedassembly techniques.

FIG. 1 illustrates a cross sectional view of two (2) roll-grooved carbonsteel pipes 102 that are coupled to one another using a mechanicaljoining apparatus 100. The carbon steel pipes are typically manufacturedto ASTM A53A, B, OR C ERW or A106 seamless steel standard that allowsthe material to be, inter alfa, welded, cut with a torch, drilled,tapped and grooved in the field. The carbon roll-grooved carbon steelpipes are separated by a gap 108 and are coupled using a coupling 104fitted with a gasket 106. These couplings are typically bolted aroundthe carbon steel pipes to be joined and have at least a portion of thecoupling positioned within the rolled groove 110 of the carbon steelpipes themselves. While roll-grooved pipe is useful for straight carbonsteel pipes, the process is complicated when various fittings (e.g.,elbows, tees, crosses, wyes, caps, laterals, and reducers (concentric oreccentric)) need to be utilized with the aforementioned roll-groovedpipe.

FIG. 2 illustrates a cross sectional view of one such mechanicallyjoined pipe fitting 200 as it exists in the prior art. Specifically,FIG. 2 illustrates a straight portion of carbon steel pipe 102 joined toan elbow pipe fitting 202. The carbon steel pipe 102 includes a rolledgroove 210 while the elbow 202 includes a groove 212 that is formedusing either: (1) a casting process; or (2) a machining process. Thecarbon steel pipe and fitting are subsequently connected using astandard coupling 204 with an accompanying gasket 206. In applicationswhere casting processes are used, the elbow fitting is typically madefrom ductile cast iron material. While the cast iron fitting iseffective in performing its intended function, the overall mechanicalstrength of the ductile cast iron possesses less strength than anequivalent carbon steel elbow, while also having a much higher cost thana welded carbon steel elbow. For example, a carbon steel elbow that isjoined using a welding process might cost on the order of about $5 USD,while an equivalent cast elbow pipe fitting would cost on the order ofabout $27 (see also Appendix A which illustrates exemplary relative costdifferences between welded pipe fittings and equivalent cast iron(grooved) pipe fittings).

In addition, ductile cast iron is generally not well suited formodification in the field as it is difficult to machine, and isotherwise not suitable for other modification processes such as weldingor tapping.

Alternatively, in applications where a cut-grooved carbon steel fittingis used, the portion 212 where the groove is machined into the carbonsteel elbow possesses much less strength than an equivalent groove madefrom a roll-grooving technique due in part to the comparatively smalleramount of material (i.e., the material removed during machining) presentin the grooved area.

In addition, the machining process is substantially complicated due tothe various complicated geometries of the various fittings used inpiping systems, thereby often necessitating skilled machinists and/orspecialized tools for manufacture.

FIG. 3 illustrates an alternative to the mechanically joined system ofFIG. 2 in which a carbon steel elbow fitting 302 is joined to a straightcarbon steel pipe 304 by a welded joint 306. While the carbon steelelbow of the welded system 300 of FIG. 3 is less costly, in terms ofmaterial costs, the assembly process is substantially more complicatedand costly then a mechanically joined system as welding processesrequire skilled welders. In addition, the welding process is much moretime consuming then an equivalent mechanically joined system.

Accordingly, despite the foregoing wide variety of joining systems inthe prior art, there remains an unsatisfied need for an improved pipefitting system that: (i) is less costly to produce then a cast ormachined pipe fitting, (ii) is easier to assemble then a welded pipefitting, (iii) possesses greater mechanical strength than an equivalentcast or machined pipe fitting, and/or (iv) is easier to modify in thefield then an equivalent cast pipe fitting.

SUMMARY OF THE INVENTION

The invention satisfies the aforementioned needs by providing improvedroll grooved pipe fitting apparatus, as well as methods formanufacturing and using the same. In a first aspect of the invention, aroll-grooved pipe fitting is disclosed. In one embodiment, theroll-grooved pipe fitting is a forged pipe fitting that includes two ormore peripheral openings with at least one of the peripheral openingshaving a roll grooved feature that facilitates the forged pipe fittingscoupling with other roll grooved apparatus. The forged pipe fittingeither: (1) includes a bend between the two or more peripheral openings;or (2) includes three or more peripheral openings.

In a second embodiment, the forged pipe fitting includes a roll groovedfeature that facilitates the forged pipe fittings coupling with otherroll grooved apparatus.

In a second aspect of the invention, a hybrid pipe fitting is disclosed.In one embodiment, the hybrid pipe fitting includes both a roll-groovedend and another end suitable for welding.

In a third aspect of the invention, a mechanically joined system isdisclosed. In one embodiment, the mechanically joined system includes aroll-grooved carbon steel pipe and a roll-grooved carbon steel fitting.

In a fourth aspect of the invention, methods of manufacturing theaforementioned roll-grooved pipe fitting and system are disclosed.

In a fifth aspect of the invention, methods of assembling theaforementioned mechanically joined system are disclosed.

In a sixth aspect of the invention, tools which manufacture theaforementioned roll-grooved pipe fitting are disclosed.

In a seventh aspect of the invention, hybrid systems that utilize bothroll-grooved joints and non roll-grooved joints are disclosed.

In an eighth aspect of the invention, business methods associated withthe aforementioned apparatus, system and methods are disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, objectives, and advantages of the invention will becomemore apparent from the detailed description set forth below when takenin conjunction with the drawings, wherein:

FIG. 1 is a cross-sectional view of an exemplary prior art mechanicallycoupled roll grooved pipe system.

FIG. 2 is a cross-sectional view of an exemplary prior art mechanicallycoupled pipe fitting system.

FIG. 3 is a cross-sectional view of an exemplary prior art coupled pipefitting system using a welding process.

FIG. 4A is a cross-sectional view of an exemplary roll groovedninety-degree elbow pipe fitting in accordance with the principles ofthe present invention.

FIG. 4B is a cross-sectional view of an exemplary roll groovedforty-five degree elbow pipe fitting in accordance with the principlesof the present invention.

FIG. 4C is a cross-sectional view of an exemplary roll grooved tee pipefitting in accordance with the principles of the present invention.

FIG. 4D is a cross-sectional view of an exemplar roll grooved cross pipefitting in accordance with the principles of the present invention.

FIG. 5 is an elevation view of an exemplary roll grooving apparatus inaccordance with the principles of the present invention.

FIG. 5A is an elevation/cross-sectional view of an exemplaryninety-degree elbow pipe fitting roll grooving setup in accordance withthe principles of the present invention.

FIG. 5B is an elevation/cross-sectional view of an exemplary tee pipefitting roll grooving setup in accordance with the principles of thepresent invention.

FIG. 5C is an elevation/cross-sectional view of an alternative tee pipefitting roll grooving setup in accordance with the principles of thepresent invention.

FIG. 5D is an elevation/cross-sectional view of yet another alternativetee pipe fitting roll grooving setup in accordance with the principlesof the present invention.

FIG. 6A-1 and FIG. 6A-2 are collectively a multi-view projection of aleverage bar for use with ninety degree elbow pipe fitting in accordancewith the principles of the present invention.

FIG. 6B is an end view of a leverage bar for use with tee pipe fittingsin accordance with the principles of the present invention.

FIG. 6C is an end view of a leverage bar for use with, inter alfa, teepipe fittings in accordance with the principles of the presentinvention.

FIG. 6D is an end view of an alternative variant of the leverage barillustrated in FIG. 6C.

FIG. 6E is a front view of an exemplary idler wheel assembly mounted toa roll grooving apparatus in accordance with the principles of thepresent invention.

FIG. 6F is a front view of an exemplary tool for correcting out of roundpipe fittings in accordance with the principles of the presentinvention.

FIG. 6G-1 and FIG. 6G-2 are collectively a multi-view projectionillustrating a flare out condition in cross-section along with anexemplary tool for correcting flare out conditions in accordance withthe principles of the present invention.

FIG. 6H is an elevation view of an alternative tool for correcting flareout conditions in accordance with the principles of the presentinvention.

FIG. 6I is a top view of the alternative tool of FIG. 6H in accordancewith the principles of the present invention.

FIG. 7 is an exemplary process flow diagram for manufacturing exemplaryroll grooved pipe fitting apparatus in accordance with the principles ofthe present invention.

FIG. 8A is a perspective view of a first exemplary prior art hybridpiping system.

FIG. 8B is a perspective view of a variant of the hybrid piping systemof FIG. 8A in accordance with the principles of the present invention.

FIG. 8C is a perspective view of a second exemplary prior art hybridpiping system.

FIG. 8D is a perspective view of a variant of the hybrid piping systemof FIG. 8C in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to the drawings wherein like numerals refer tolike parts throughout.

Overview

In one salient aspect of the invention, various pipe fittings that areused in the assembly of a variety of mechanically joined piping systemsare roll-grooved so that they can be mechanically joined directly withother like pipe fittings and/or roll grooved straight pipe, therebysubstantially simplifying assembly.

In addition, the aforementioned roll grooved pipe fittings could also beused as hybrid components, whereby one or more joints are joined using awelding technique while other joint(s) on the same pipe fitting can beused using a mechanically joined method.

Moreover, as the variety of materials that can be used is increased withthe aforementioned roll grooved pipe fitting, the materials that can bechosen can be: (1) less expensive to procure; and/or (2) easier tomodify in the field, thereby substantially improving the productivity ofthe installers who install these mechanically joined piping systems.

Methods and apparatus for manufacturing these aforementioned rollgrooved pipe fittings are also disclosed, which address both the rollgrooving process itself, as well as various methodology and apparatusfor correcting deformations (e.g., out of round conditions, flare-outconditions, etc.) that can occur as a result of the roll groovingprocess.

Methods for using the aforementioned apparatus are also disclosed.

Exemplary Embodiments

Exemplary embodiments of the apparatus and methods of the presentinvention are now described in detail. It will be appreciated that whilethe roll-grooved pipe fittings described herein are primarilymanufactured from carbon steel in compliance with ASTM A234/A234M, othermaterials or alloys including without limitation stainless steel,copper, and aluminum could be readily substituted, the use of carbonsteel merely being exemplary.

Moreover, it will be appreciated that while the various embodimentsshown and described herein are described primarily in the context ofstandard weight pipe thicknesses up to about three-eighths (⅜) of aninch thick (depending on the overall diameter of the fitting), it isappreciated that larger non-standard pipe thicknesses can also benefitfrom the machinery and manufacturing processes described herein.

Roll-Grooved Fitting Apparatus

Referring now to FIGS. 4A-4D, various pipe fittings are illustrated incross-section so that the respective geometry of the various grooves aremore easily visible. FIG. 4A illustrates an exemplary ninety-degree(90°) elbow pipe fitting 410. The pipe fitting illustrated in FIG. 4A ispreferably manufactured from carbon steel in compliance with ASTMA234/A234M. The elbow includes a rolled groove 402 that is present onboth ends of the elbow. In addition, the elbow also included a deformedportion 404 that is resultant from the roll-grooving process describedsubsequently herein with respect to FIGS. 5-5A. FIG. 4B illustrates analternative elbow variant comprised of a forty-five degree (45°) elbowfitting 420 with accompanying grooves 402 and deformed portions 404.Similarly, FIG. 4C illustrates a tee pipe fitting 440 with accompanyinggrooves 402 and deformed portions 404 while FIG. 4D illustrates a crosspipe fitting 430 with accompanying grooves 402 and deformed portions404.

In addition to those pipe fittings illustrated with respect to FIGS.4A-4D, other pipe fittings that are roll-grooved are envisioned andinclude, without limitation: (1) drain elbows (i.e., elbows with atapped hole or welded thread-o-let); (2) standard or custom angledelbows (e.g. twenty two and a half degree (22.5°) elbows; eleven and aquarter degree elbows (11.25°), etc.); (3) long radius elbows; (4)reducing base support elbows; (5) adapter elbows; (6) reducing tees; (7)reducing crosses; (8) laterals; (9) tee wyes; (10) true wyes; (11)reducing laterals; (12) reducing tee wyes; (13) caps; (14) bull plugs;(15) concentric reducers; and (16) eccentric reducers, etc.Additionally, hybrid pipe fittings (not shown) are also envisioned,which include both a roll-grooved interface and an interface suitablefor well-known welding processes.

Furthermore, because the application of the roll-grooving processesdescribed herein can readily be applied to virtually any type offitting, customization of fittings is now possible. For example, astandard ninety degree (90°) elbow can be cut to almost any desirableangle (e.g. twenty-nine degrees (29°)) and a rolled groove can thensubsequently be added to the cut end. Such customization has heretoforebeen unachievable. With the growing diversity of complex geometries intoday's architectural designs, the ability to easily produce customroll-grooved fittings presents a tremendous time and cost advantage overprior art cast fittings.

Manufacturing Methodology

Referring now to FIG. 5, a hydraulic roll grooving apparatus 500 usefulin manufacturing the roll-grooved fitting apparatus discussed previouslyherein is shown and described in detail. The roll grooving apparatus isgenerally similar in construction to that disclosed in U.S. Pat. No.3,903,722 to Thau, Jr., et al. filed on Jun. 28, 1974 and entitled “RollGrooving Tool”, the contents of which are incorporated herein byreference in its entirety, although other approaches may be used withequal success.

In its simplest form, the hydraulic roll grooving apparatus includes agrooving roll 510 that is allowed to rotate about shaft 514. The shaft514 is contained within machine body 512 that is further designed toactuate along the Z-axis 516 and is driven by a hydraulic actuator 518.Opposite the grooving roll 510 is a backup roll 502. The backup rollincludes a knurled outer surface 506 on its outer diameter (i.e., thesurface adapted to engage the interior of the fitting to be rollgrooved). The backup roll also includes a relief cavity 504 that issized to accommodate the deformed portion of the grooves shown in, forexample, FIGS. 4A-4D. The front face of the backup roll also includes arelief feature 508 (such as a chamfer) that is sized so as toaccommodate any obstructing features (such as a radius) present on thefitting to be roll grooved. Backup rolls are typically manufactured suchthat the two portions opposite the relief cavity 504 are symmetric insize. However, material needs to be removed (i.e., relief feature 508)in order to accommodate features that are present on various ones ofpipe fitting geometry. Note that grooving roll also possesses asimilarly manufactured relief feature on the front portion of the roll.A backstop 520 (which may be custom manufactured for example) is alsoincluded which helps maintain the fitting to be grooved in properalignment during the roll grooving process. This custom manufacturedbackstop is machined so as fit under the backup roll whilesimultaneously providing support for the specific geometry of the pipefitting to be roll grooved.

Referring now to FIG. 5A, a machine set up for the manufacture of rolledgrooves into a ninety degree (90°) elbow 410 is illustrated. Thehydraulic roll grooving apparatus is as described previously withrespect to FIG. 5, and includes a custom backstop created (i.e.,fabricated) and sized to accommodate the specific geometry shown. Aninety degree (90°) elbow is illustrated as being installed over thebackup roll 502. Installed around the ninety degree (90°) elbow is aleverage bar 530 (FIG. 6A) which will rotate as illustrated when theelbow is being roll grooved. Preferably, the leverage bar is configuredso as to rotate about an axis that is collinear with the axis ofrotation for the backup roll 502; however it is understood that inpractice this can require significant effort to achieve. Accordingly, itis generally acceptable that the leverage bar merely maintains anorientation in which its longitudinal axis is generally parallel withthe axis of rotation for the backup roll in lieu of the foregoing.

FIG. 5B illustrates a machine set up for the manufacture of rolledgrooves into the orthogonal branch of a tee 440. Again, the backstop 520is sized to accommodate the specific geometry of the tee fitting. Theleverage bar 540 (FIG. 6B) includes an interface portion 544 sized toaccommodate the outer surface shape of the tee fitting, and alsoincludes clamps 542 which securely attach the tee fitting to theleverage bar during the roll grooving process. Again, the leverage baris configured so that its axis of rotation is preferably collinear orparallel with the axis of rotation for the backup roll.

FIG. 5C illustrates the roll grooving of the opposing openings for thetee fitting 440 shown in FIG. 5B and FIG. 4C. The leverage bar 550 isattached to an outer diameter portion of the tee fitting via a clamp552. Accordingly, during the roll grooving process, the leverage barwill rotate about the axis of rotation for the backup roll, whilesimultaneously maintaining an orientation that is generally parallelwith this axis of rotation. FIG. 5D illustrates a variant of the set upillustrated in FIG. 5C. However, in this illustrated embodiment, theleverage bar 560 includes a bracket 564 that in combination with theclamp portions 562 positions the leverage bar 560 so that it isgenerally concentric with the rotational axis of the backup roll.

Referring now to FIGS. 6A-1 and 6A-2, an exemplary multi-view projectionof the leverage bar 530 utilized in the machine set up illustrated inFIG. 5A is shown and described in detail. Specifically, as can be seenin FIG. 6A-1, the leverage bar includes an upper 532 and lower clamp 534that are held together by bolts 536. These clamps are sized so as toaccommodate the external periphery of the particular pipe fitting beingroll grooved. In addition, and as can be seen in FIG. 6A-2 leverage barhandle 538 is positioned at a predetermined angle 537 with respect tothe upper and lower clamps via a transition element 535 so that thedesired relationship between the roll grooving apparatus and theleverage bar handle is maintained as discussed with regards to FIG. 5Asupra.

FIG. 6B illustrates an end view of the leverage bar 540 illustrated inthe machine setup of the embodiment of FIG. 5B. The leverage barincludes an interfacing portion 544 that possesses a radius sized toaccommodate the external periphery of the pipe fitting to be rollgrooved. In addition, leverage bar clamps 542 are used to securelyattach the leverage bar to the pipe fitting to be roll grooved.

FIG. 6C illustrates an end view of the leverage bar 550 illustrated inthe machine setup of FIG. 5C. Similar to the leverage bar shown in FIG.6A, the illustrated leverage bar includes an upper 552 and lower clamp554 held together by bolts 556 and sized to accommodate the externalperiphery of the pipe fitting to be roll grooved. The leverage bar alsoincludes a handle that is orthogonal to the clamps.

FIG. 6D illustrates an end view of the exemplary embodiment of theleverage bar 560 illustrated in the machine setup of FIG. 5D andincludes and upper 562 and lower clamp 566 that are coupled to oneanother via bolts 568. In addition, bracket 564 centers the leverage barhandle along the rotational axis in order to aid in the roll grooving ofthe attached pipe fitting (not shown).

FIG. 6E illustrates an exemplary custom idler wheel assembly 600 usefulin helping to maintain proper alignment of the pipe fittings being rollgrooved using the roll grooving apparatus 500 illustrated in FIG. 5. Themain body of the idler wheel assembly is secured to the roll groovingapparatus via a number of bolts 606. The adjustable portion 602 of theidler wheel assembly moves along a defined axis and is adjusted usinghand crank 606 so that idler wheel 604 is in contact with the pipefitting to be roll grooved. The idler wheel is also allowed to rotatefreely when in contact with the pipe fitting.

Referring now to FIG. 6F, an exemplary embodiment of a tooling apparatus620 for correcting out of round roll grooved pipe fittings is shown anddescribed in detail. The tooling apparatus includes an upper anvil 622and lower die 624 which includes a curved portion that is sized so as tobe able to reshape a roll grooved pipe fitting back into its desiredshape if the pipe fitting becomes out of round during the roll groovingprocess. The upper anvil remains stationary while the lower die isallowed to actuate along frame 626 using a hydraulic piston 628.

FIG. 6G-1 illustrates a typical “flare-out” condition 630 that hasoccurred on a pipe fitting 650 during a roll grooving operation inaccordance with embodiments of the invention described herein. Aflare-out occurs when the outer periphery or tail end of the pipefitting (i.e. the portion of the pipe external to the groove 652) isdeflected outward as a result of improper axial alignment during theroll grooving process. While the Assignee hereof notes that theseflare-out conditions are typically within tolerance (i.e. the groovedfitting with this flare-out condition are otherwise useable), theseflare-outs are undesirable aesthetically and hence can potentially beundesirably perceived by consumers. In one embodiment, and as shown inFIG. 6G-2 this flare-out condition is corrected using a freely spinninganvil 632 in combination with a die wheel 634 that is positioned againstthe flared out portion of the pipe fitting using a hydraulic jack 636.

Referring now to FIGS. 6H-6I, an exemplary tool 660 for correctingflare-out conditions on a grooved fitting 650 is shown and described indetail. While a grooved elbow fitting is illustrated in FIG. 6H, it isappreciated that any grooved fitting such as, and without limitation,the tee pipe fitting illustrated in FIG. 4C, and the cross pipe fittingillustrated in FIG. 4D could also be readily corrected using the toolillustrated in FIGS. 6H-6I. The fitting is positioned over a drive wheel670, which drives the rotation of the grooved fitting within theflare-out correcting tool 660. The drive wheel includes a relief cavity672 which accommodates the deformed portion of the grooved fitting. Theouter diameter of the drive wheel is sized so as to be just smaller thanthe inner diameter of the grooved fitting as measured from the deformedportion of the groove. Accordingly, the grooved fitting can simply bepositioned over the drive wheel prior to the correction of the flare outcondition. The drive wheel is driven by a gear reduction mechanism 674which is in turn driven by a motor 676. In an exemplary embodiment, themotor is electrical and is sized appropriately for the grooved fittingsbeing corrected. Furthermore, the motor will desirably include a DCvariable speed motor which enables a single motor to be used on avariety of different sized fittings.

Positioned on the work surface 668 of the flare-out repair tool 660 are,in an exemplary embodiment, two (2) idler wheels 680 and a flare-outcorrecting pressure roller 662. In the illustrated embodiment, theflare-out correcting pressure roller 662 includes a bearing surface 664used to straighten and align the flare out condition on the groovedfitting. The flare-out correcting pressure roller is positioned within aslot (not shown) contained within the work surface 668 and is coupled toa piston (not shown) which drives the flare-out correcting pressureroller into the flared portion of the fitting. This piston may bepneumatically or hydraulically driven. Furthermore, the flare-outcorrecting pressure roller will also incorporate a stop feature (notshown) which prevents the flare-out correcting roller fromover-compensating the flared out portion of the grooved fitting (i.e.deforming the flared out portion past true).

The idler wheels 680, like the flare-out correcting roller, residewithin similar slots on the work surface and are similarly coupled to apiston. These idler wheels also include a groove fitting portion 682.While the groove fitting portion of the idler wheels are shownpositioned within the middle portion of the idler wheel, it isappreciated that it may be desirable to move the relative position ofthe groove fitting portion (e.g. towards the top of the idler wheel) inorder to accommodate various fitting geometries and clearances. Inaddition, depending on the geometry of the grooved fitting to becorrected, the elevation of the idler wheels can be adjusted toaccommodate various fitting geometries. As the grooved portion of thefitting acts as the geodetic datum from which the flare-out condition ismeasured, the groove fitting portion of the idler wheel acts to firmlycouple and align the grooved fitting onto the work surface of the tool.Accordingly, by securing the grooved fitting vis-à-vis the groove, theanvil 670 and flare-out correcting roller 662 can ensure that anycorrections to the flared out condition of the grooved fitting arestraight and true. In addition, and similar to features described withrespect to the flare-out correcting roller, the idler wheels will alsoincorporate stops to prevent the over-compression of the groovedfitting.

FIG. 6I illustrates a top down view of the flare-out correcting tool 660illustrated in FIG. 6H. Specifically, the relative positioning of theidler wheels 680 with respect to the flare-out correcting die 662 arenow visible. The flare-out correcting roller 662 is positioned within arespective slot 667 which enables the flare-out correcting roller tofreely travel along the length of the slot. The idler wheels aredisposed within respective slots 666 on an opposing side of the drivewheel 670 with the flare-out correcting tool. These idler wheels areconfigured to be positioned along their respective idler wheel axes 686using pistons (as described previously herein). These idler wheel axesare separated by an angle theta (θ), which is in an exemplary embodimentabout sixty degrees (60°). The angle chosen is ideally selected based ona number of factors including: (1) the diameter of the groovedfitting(s); (2) the number of idler wheels (e.g. two (2)); and (3) thediameter of the idler wheels themselves. By taking into account thesevarious factors when choosing the angle theta (θ), various diametergrooved fittings can be corrected for flare out conditions whileminimizing the components that need to be swapped out within theflare-out correcting tool 660. For example, as the idler wheels 680travel within their slots 666 along their respective axes 686, onelimiting factor for the size of the grooved fitting placed onto the toolis how close the idler wheels can get to the center point 688 of thedrive wheel 670 before they interfere with one another. Accordingly, bychoosing the proper angle theta (θ), an operator can use the same idlerwheels for a variety of different grooved fitting sizes therebyeconomizing on the operation of the tool 660 by minimizing down time.

Referring now to FIG. 7, an exemplary weld fitting roll groovingprocedure 700 is shown. At step 702, a pipe fitting is procured andmodified (if necessary). In an exemplary embodiment, the pipe fittingprocured is a butt-weld carbon steel pipe fitting in accordance withASTM A234/A234M. See for example FIG. 3 that illustrates a ninety-degree(90°) elbow 302. Using the elbow of FIG. 3 as an example, the bevelededge adjacent the weld interface is machined so as to provide a squaresurface for the roll grooving process.

At step 704, the roll grooving apparatus is set up. In one embodiment,the set up process includes installing a custom built backstop that issized in accordance with the fitting to be roll grooved. The backstop isinstalled underneath the backup roll and aids in maintaining properalignment of the pipe fitting during the roll grooving process. Inaddition, the backup roll and grooving roll is machined (if necessary)to ensure adequate clearance between any obstructing features (e.g., theradius on the elbow fitting) and subsequently installed onto the rollgrooving apparatus. If the roll grooving apparatus is equipped withsafety guards, these are removed and/or modified so that the pipefitting will maintain clearance throughout the entire rotation of thefitting during the roll grooving process. The free spinning custom builtidler wheel assembly (FIG. 6E) is adjusted so that it engages thegasket-seating surface of the pipe fitting, which is in an exemplaryembodiment, resident about three quarters of an inch from the end of thepipe fitting.

At step 706, the leverage bar (see e.g. FIGS. 5A-6D) is installed ontothe pipe fitting. In an exemplary embodiment, the leverage bar isclamped to the backside of the fitting and is sized in accordance withthe underlying size and shape of the fitting. The leverage bar is thenutilized by an operator so as to maintain the pipe fitting in alignmentwith the grooving roll and backup roll. In other words, the operatormaintains the pipe fitting in an orientation in which the longitudinalaxis of the rolled grooves maintains a parallel relationship with thelongitudinal axis of the pipe fitting opening. The operator mayaccomplish this, in an exemplary embodiment, by manually controlling theamount of pressure or force being applied to the pipe fitting so as tokeep it in the correct position between wheels for the part to trackproperly.

At step 708, the pipe fitting is roll grooved on the roll groovingapparatus. As described above, in an exemplary embodiment, the leveragebar is positioned manually by an operator who manipulates the leveragebar so as to maintain proper alignment as the pipe fitting is rotatedduring the roll grooving process. Alternatively, the leverage bar isutilized within an alignment apparatus (not shown) that maintains thepipe fitting properly aligned as the roll grooving apparatus rotates thepipe fitting.

At step 710, the roll grooved pipe fitting is inspected to determinewhether the roll grooving process has taken the pipe fitting opening outof round or whether a flared-out condition has occurred on the edge ofthe pipe fitting. As previously described, a flared-out condition mayoccur when the outer periphery of the pipe fitting is deflected outwardas a result of improper axial alignment during the roll groovingprocess.

If the roll grooved pipe fitting is out of round, or has flared-out, atstep 712 the pipe fitting is reshaped to correct the deformation in theroll grooved pipe fitting. For example, if the pipe fitting becomesout-of-round, the fitting is placed in a press (see e.g. FIG. 6F) withinterchangeable dies that are shaped according to the diameter of thefitting that matches the outer circumference of the fitting. A hydraulicpress is then used in conjunction with the matched interchangeable dieand the out-of-round condition is corrected. Alternatively, or incombination with correcting the aforementioned out-of-round condition,if the face of the pipe fitting is flared out, the fitting is placed ina machine that applies a force to the gasket-seating surface of the pipefitting as it rotates via the use of a hydraulic idler wheel thatengages the fitting. See for example, FIGS. 6G-6I discussed supra. Theapplied force created between the drive wheel (similar to theaforementioned backup wheel) and the idler wheel pushes the flare backinto its original position. If the grooved pipe fitting is bothout-of-round and flared, the two corrective processes can be applied insuccession, i.e. correcting the out-of-round condition followed bycorrecting the flared out condition or vice versa.

At step 714, the roll grooved pipe fitting is packaged for shipment. Inone embodiment, the packaging process begins by ensuring that thegasket-seating surface of the pipe fitting is smoothed and free fromburrs. If not, this surface is processed (e.g., sanded), and all burrsare removed. Next, a protective end cap is placed onto the end of thefitting before placed into its packaging for shipment. In an exemplaryembodiment, the protective end cap and/or finished fitting is markedwith the company's name, and other pertinent information. In addition,each roll grooved fitting will carry the original manufacturerspecifications that are typically stamped into the fitting by theoriginal manufacturer of the part. The fitting is now ready for resaleto distributors, vendors and companies.

Methods of Use

Referring now to FIG. 8A, a first exemplary hybrid system 800 as itexists in the prior art is illustrated. Specifically, the hybrid systemillustrated in FIG. 8A includes a couple of types of fittings 820, 830joined together via welds to standard steel straight lengths of pipe818. In an exemplary embodiment, these standard straight lengths of pipecomprises six-inch diameter standard carbon steel pipe 818, while theelbows comprise six-inch diameter standard ninety degree (90°) carbonsteel elbow fittings 820 along with a standard carbon steel tee fitting830. In order to attach such a system to other lengths of standardcarbon steel pipe via a mechanical (grooved) connection, short lengthsof carbon steel 810, with grooves added to one end, are often added inorder to join the welded portions of the system to the mechanicallyattached portions of the system.

FIG. 8B illustrates an exemplary hybrid system 840 that is similar tothat shown in FIG. 8A, except that it utilizes the grooved pipe fittingembodiments described previously herein. Specifically, the short lengthsof carbon steel pipe which were added in FIG. 8A can now be obviated asthe grooves 824, 834 can be incorporated directly onto the elbowfittings 822 and tee fitting 832, respectively. Accordingly, for thissmall sample section of a hybrid system 840, three (3) cuts and three(3) welds no longer need to be performed thereby substantially reducingsystem complexity and assembly time. Additionally, this not only resultsin a more streamlined assembly process, but also results in the abilityto make smaller turns and offsets over prior art techniques. Such asystem is also particularly useful in areas where the amount of spacefor running pipe is limited.

FIG. 8C illustrates an alternative hybrid system 850 as it exists in theprior art. In one embodiment, the hybrid system of FIG. 8C includesten-inch standard carbon steel pipe 856, 858, 866; eight-inch standardcarbon steel pipe 864; a ten-inch standard carbon steel tee 854; and aten-inch by eight-inch standard carbon steel reducing tee 852. Thehybrid system includes welded joints 860 as well as grooved joints 862.However, again, relatively short lengths of carbon steel pipe 856, 866and 864 need to be added in order to join the welded portions of thesystem to the mechanically joined portions of the system.

FIG. 8D illustrates an exemplary hybrid system 870 that is similar tothat shown in FIG. 8C, except that it now incorporates the grooved pipefitting embodiments described previously herein. Specifically, the shortlengths of carbon steel pipe which were added in FIG. 8C are nowobviated as the grooves 882 are incorporated directly onto the fittings880, 890 themselves. Accordingly, for this small section of a hybridsystem 870, four (4) cuts and four (4) welds no longer need to beperformed thereby substantially reducing system complexity and assemblytime. Similar to the embodiment illustrated in FIG. 8B, this not onlyresults in a more streamlined assembly process, but also incorporatesthe ability to make smaller offsets, over prior art techniques.

It can be appreciated that while certain aspects of the invention havebeen described in terms of a specific sequence of steps of a method,these descriptions are only illustrative of the broader methods of theinvention, and may be modified as required by the particularapplication. Certain steps may be rendered unnecessary or optional undercertain circumstances. Additionally, certain steps or functionality maybe added to the disclosed embodiments, or the order of performance oftwo or more steps permuted. All such variations are considered to beencompassed within the invention disclosed and claimed herein.

While the above detailed description has shown, described, and pointedout novel features of the invention as applied to various embodiments,it will be understood that various omissions, substitutions, and changesin the form and details of the device or process illustrated may be madeby those skilled in the art without departing from the invention. Theforegoing description is of the best mode presently contemplated ofcarrying out the invention. This description is in no way meant to belimiting, but rather should be taken as illustrative of the generalprinciples of the invention. The scope of the invention should bedetermined with reference to the claims.

What is claimed is:
 1. A method of manufacturing a roll-grooved forgedcarbon steel fitting, the method comprising: obtaining a forged carbonsteel fitting, the forged carbon steel fitting comprising a tubularstructure having one or more bends associated therewith; placing theforged carbon steel fitting onto a roll grooving apparatus; installing aleverage bar onto the forged carbon steel fitting; and roll-grooving theforged carbon steel fitting in order to produce the roll-grooved forgedcarbon steel fitting; wherein the installing of the leverage bar ontothe forged carbon steel fitting comprises installing the leverage barsuch that a portion of the leverage bar rotates about an axis that iscollinear with an axis of rotation for the roll grooving apparatus. 2.The method of claim 1, further comprising modifying the obtained forgedcarbon steel fitting prior to the placing, the modifying comprisingremoving a beveled edge adjacent to an opening of the tubular structure.3. The method of claim 1, wherein prior to the placing, installing acustom backstop onto the roll grooving apparatus.
 4. The method of claim1, further comprising manipulating the leverage bar to maintainalignment during the roll-grooving.
 5. The method of claim 4, furthercomprising inspecting the roll-grooved forged carbon steel fitting,subsequent to the roll-grooving, in order to determine out of roundand/or a flared-out condition.
 6. The method of claim 5, wherein whenthe inspecting reveals the out of round and/or the flared-out condition,re-shaping the roll-grooved forged carbon steel fitting.
 7. The methodof claim 6, wherein the re-shaping of the roll-grooved forged carbonsteel fitting comprises using a flare-out correcting tool in order tocorrect the out of round and/or the flared-out condition.
 8. A method ofmanufacturing a roll-grooved forged carbon steel fitting, the methodcomprising: obtaining a forged carbon steel fitting, the forged carbonsteel fitting comprising a tubular structure having one or more bendsassociated therewith; placing the forged carbon steel fitting onto aroll grooving apparatus; installing a leverage bar onto the forgedcarbon steel fitting; and roll-grooving the forged carbon steel fittingin order to produce the roll-grooved forged carbon steel fitting;wherein the installing of the leverage bar onto the forged carbon steelfitting comprises securing the leverage bar adjacent to a peripheralopening of the forged carbon steel fitting.
 9. The method of claim 8,further comprising modifying the obtained forged carbon steel fittingprior to the placing, the modifying comprising removing a beveled edgeadjacent to an opening of the tubular structure.
 10. The method of claim8, wherein prior to the placing, installing a custom backstop onto theroll grooving apparatus.
 11. The method of claim 8, further comprisingmanipulating the leverage bar to maintain alignment during theroll-grooving.
 12. The method of claim 11, further comprising inspectingthe roll-grooved forged carbon steel fitting, subsequent to theroll-grooving, in order to determine out of round and/or a flared-outcondition.
 13. The method of claim 12, wherein when the inspectingreveals the out of round and/or the flared-out condition, re-shaping theroll-grooved forged carbon steel fitting.
 14. The method of claim 13,wherein the re-shaping of the roll-grooved forged carbon steel fittingcomprises using a flare-out correcting tool in order to correct the outof round and/or the flared-out condition.
 15. A method of manufacturinga roll-grooved forged carbon steel fitting, the method comprising:obtaining a forged carbon steel fitting, the forged carbon steel fittingcomprising a tubular structure having one or more bends associatedtherewith; placing the forged carbon steel fitting onto a roll groovingapparatus; installing a leverage bar onto the forged carbon steelfitting; and roll-grooving the forged carbon steel fitting in order toproduce the roll-grooved forged carbon steel fitting; wherein theinstalling of the leverage bar onto the forged carbon steel fittingcomprises securing the leverage bar to a central location of the forgedcarbon steel fitting, the central location being disposed away from openapertures for the tubular structure.
 16. The method of claim 15, furthercomprising modifying the obtained forged carbon steel fitting prior tothe placing, the modifying comprising removing a beveled edge adjacentto an opening of the tubular structure.
 17. The method of claim 15,wherein prior to the placing, installing a custom backstop onto the rollgrooving apparatus.
 18. The method of claim 15, further comprisingmanipulating the leverage bar to maintain alignment during theroll-grooving.
 19. The method of claim 18, further comprising inspectingthe roll-grooved forged carbon steel fitting, subsequent to theroll-grooving, in order to determine out of round and/or a flared-outcondition.
 20. The method of claim 19, wherein when the inspectingreveals the out of round and/or the flared-out condition, re-shaping theroll-grooved forged carbon steel fitting; and wherein the re-shaping ofthe roll-grooved forged carbon steel fitting comprises using a flare-outcorrecting tool in order to correct the out of round and/or theflared-out condition.